Structural Connection Aligning Device and Method of Use Thereof

ABSTRACT

A device and method of use for aligning structural elements to be connected is presented. In particular, the present invention relates to providing an end of a first structural element and an end of a second structural element; providing an aligning device including a head configured to be removably secured proximate the end of the first structural element, the aligning device further including an alignment element attached to the head, the alignment element having a rotatably secured plunging body extendable from the head; extending the plunging body from the head to non-rotatably engage the second structural element; and moving the non-rotatably engaged second structural element via extension of the plunging body to align the end of the second structural element with the end of the first structural element.

RELATED APPLICATION

The present invention is a continuation-in-part of co-pending U.S.patent application Ser. No. 11/036,848, filed Jan. 14, 2005 and entitled“Pipe Aligning Device and Method of Use Thereof” and is incorporatedherein by reference in its entirety.

BACKGROUND OF THE INVENTION

1. Field of Invention

The present invention relates to a device and method of use thereof forthe alignment structural connections. In particular, the presentinvention relates to the device having particular features, and themethod for its use, for aligning of pipes, fittings, rods, beams,sheets, angle-iron, flat-iron, I-beams, rounds and the like, so as toeasily provide tack welds prior to welding.

2. Related Art

In the field of welding, efforts toward devices and methods to assist inaligning pipes, pipe elements and other connecting structures arecontinuously being made. Devices and methods have been developed tofacilitate structural alignment for appropriate welding and connection.However, existing devices and methods are often bulky, user unfriendly,not capable of use with varying size structures, inaccurate, imprecise,and time and labor intensive.

Therefore a need exists for a device and method of use for the alignmentof pipes, pipe elements, and other structures which overcomes at leastone of the aforementioned deficiencies and others that provides a deviceand method for efficient, adjustable, easy, accurate, and precisealignment of pipes and pipe elements.

SUMMARY OF THE INVENTION

One aspect of the present invention an aligning device comprising: ahead configured to receive a first element and a second element; and atleast one alignment element wherein said alignment element axiallyaligns said first element with said second element.

A second aspect of the present invention is An aligning devicecomprising: a handle; a head configured to receive a first element and asecond element, wherein said head is configured to be removablyattachable to a handle; and at least one alignment element wherein saidalignment element axially aligns said first element with said secondelement.

A third aspect of the present invention is an aligning devicecomprising: a head configured to receive a first element and a secondelement, wherein said head is configured to be removably attachable to ahandle.

A fourth aspect of the present invention is an aligning devicecomprising: an alignment element removably attachable to an alignmenthead, wherein said alignment head is configured to receive a firstelement and a second element.

A fifth aspect of the present invention is an aligning methodcomprising: providing a first element and a second element; providing ahead configured to receive said first element and said second element,wherein said head includes a least one alignment element further whereinsaid alignment element is for axially aligning said first element withsaid second element; and axially aligning said first element with saidsecond element.

A sixth aspect of the present invention is An aligning methodcomprising: providing a first element and a second element; providing ahead configured to receive said first element and said second element;attaching to said head a plurality of tack weld gap elements configuredto set a tack weld gap between said first element and said secondelement; and setting said tack weld gap between said first element andsaid second element.

A seventh aspect of the present invention is An aligning methodcomprising: providing a first element and a second element; providing aremovably attachable alignment element configured to fit an alignmenthead, wherein said alignment head is configured to receive and fit saidfirst element and said second element; and axially aligning said firstelement with said second element.

An eighth aspect of the present invention provides a structuralconnection aligning device comprising: an alignment head; at least onealignment element attached to the alignment head, the at least onealignment element having a plunging body extendable from the alignmenthead; and a drive member operable with the alignment element, whereinplunging body is prevented from rotating when the drive member contactsthe plunging body to move the plunging body.

A ninth aspect of the present invention provides a structural connectionaligning device comprising: an alignment head configured to be removablysecured proximate an end of a first structural element; and an alignmentelement attached to the alignment head, the alignment element having arotatably secured plunging body that extends from the alignment head andengages an end of a second structural element when the alignment head isremovably secured proximate the end of the first structural element.

A tenth aspect of the present invention provides a structural connectionaligning method comprising: providing an end of a first structuralelement and an end of a second structural element to be connected;providing an aligning device including a head configured to be removablypositioned proximate the end of the first structural element, thealigning device further including an alignment element attached to thehead, the alignment element having a rotatably secured plunging bodyextendable from the head; extending the plunging body from the head tonon-rotatably engage the second structural element; and moving thenon-rotatably engaged second structural element via extension of theplunging body to align the end of the second structural element with theend of the first structural element.

An eleventh aspect of the present invention provides a structuralconnection aligning device comprising: an alignment head; at least onealignment element attached to the alignment head, the at least onealignment element having a plunging body extendable from the alignmenthead, wherein the plunging body includes a contact area contoured tomatch the curved outer surface shape of a structural element to bealigned by the aligning device; and a drive member, wherein the drivemember contacts the plunging body to move the plunging body.

BRIEF DESCRIPTION OF THE DRAWINGS

The features of the present invention will best be understood from adetailed description of the invention and an embodiment thereof selectedfor the purpose of illustration and shown in the accompanying drawing inwhich:

FIG. 1 depicts a perspective view of an embodiment of an aligningdevice, in accordance with the present invention;

FIG. 2A depicts a side sectional view of an embodiment the aligningdevice, in a closed configuration, in accordance with the presentinvention;

FIG. 2B depicts a side sectional view of an embodiment of the aligningdevice, in an open configuration, in accordance with the presentinvention;

FIG. 3 depicts a top view of an embodiment of a portion of the aligningdevice, in accordance with the present invention;

FIG. 4A depicts a perspective view of an embodiment of an alignmentelement of the device, in accordance with present invention;

FIG. 4B depicts a side perspective view of an embodiment of thealignment element of the device of FIG. 4A, in accordance with thepresent invention;

FIG. 4C depicts a perspective view of a second embodiment of analignment element of the device, in accordance with the presentinvention;

FIG. 4D depicts a side perspective view of the second embodiment of thealignment element of the device, in accordance with the presentinvention;

FIG. 4E depicts a perspective view of a third embodiment of thealignment element of the device, in accordance with the presentinvention;

FIG. 4F depicts a side perspective view of the third embodiment of thealignment element of the device, in accordance with the presentinvention;

FIG. 5 depicts a perspective view of an embodiment of a tack weld gapshim, in accordance with the present invention;

FIG. 6 depicts a side sectional view of another embodiment of analigning device, in an open configuration, in accordance with thepresent invention;

FIG. 7A depicts a blown-up partial sectional view of an embodiment of analignment element operable with an embodiment of a head to engage astructural element to be aligned, in accordance with the presentinvention;

FIG. 7B depicts a blown-up partial sectional view of another embodimentof an alignment element operable with an embodiment of a head to engagea structural element to be aligned, in accordance with the presentinvention;

FIG. 8A depicts a side perspective view of an embodiment of a plungingbody, in accordance with the present invention;

FIG. 8B depicts an bottom end view of an embodiment of a plunging body,in accordance with the present invention;

FIG. 8C depicts a side view of an embodiment of a plunging body, inaccordance with the present invention;

FIG. 9A depicts a vertical side view of an embodiment of a cartridge, inaccordance with the present invention;

FIG. 9B depicts a side perspective view of an embodiment of a cartridge,in accordance with the present invention;

FIG. 9C depicts a bottom end view of an embodiment of a cartridge, inaccordance with the present invention;

FIG. 9D depicts a horizontal side view of an embodiment of a cartridge,in accordance with the present invention;

FIG. 9E depicts a top end view of an embodiment of a cartridge, inaccordance with the present invention

FIG. 10A depicts a side sectional view of still another embodiment of analigning device prior to alignment of structural elements, in accordancewith the present invention;

FIG. 10B depicts a side sectional view of the embodiment of the aligningdevice of FIG. 10A following alignment of structural elements, inaccordance with the present invention;

FIG. 11 depicts a side view of a further embodiment of an aligningdevice, wherein the handle is depicted in a range of positions, inaccordance with the present invention;

FIG. 12 depicts a side view of the embodiment of the aligning device ofFIG. 11 without alignment elements or tack shims shown, wherein thehandle is depicted in a fully closed position, in accordance with thepresent invention;

FIG. 13 depicts a side view of the embodiment of the aligning device ofFIG. 11 without alignment elements or tack shims shown, wherein thehandle is depicted in a fully open position allowing a structuralelement to be inserted within the alignment head, in accordance with thepresent invention;

FIG. 14 depicts a side view of the embodiment of the aligning device ofFIG. 11, wherein the structural element has been inserted within thealignment head while the handle is in an open position, in accordancewith the present invention;

FIG. 15 depicts a side view of the embodiment of the aligning device ofFIG. 11, wherein the structural element has been inserted within thealignment head while the handle is maneuvered toward a closed positionbringing the alignment elements closer to the structural element, inaccordance with the present invention;

FIG. 16 depicts a side view of the embodiment of the aligning device ofFIG. 11, wherein the structural element has been inserted within thealignment head while the handle is maneuvered further toward a closedposition bringing the alignment elements into contact with thestructural element, in accordance with the present invention; and

FIG. 17 depicts a side view of a still further embodiment of an aligningdevice having a pressure mechanism including a manually activated pawlratchet, in accordance with the present invention.

DETAILED DESCRIPTION OF THE INVENTION

Although certain embodiments of the present invention will be shown anddescribed in detail, it should be understood that various changes andmodifications may be made without departing from the scope of theappended claims. The scope of the present invention will in no way belimited to the number of constituting components, the materials thereof,the shapes thereof, the relative arrangement thereof, etc . . . , andare disclosed simply as an example of an embodiment. The features andadvantages of the present invention are illustrated in detail in theaccompanying drawing, wherein like reference numeral refer to likeelements throughout the drawings. Although the drawings are intended toillustrate the present invention, the drawings are not necessarily drawnto scale.

FIG. 1 depicts a perspective view of the device 1 for aligning pipeelements, in accordance with the present invention. The device 1comprises: an alignment head 20, alignment elements 60, a pressuremechanism 70, a handle 50, and a tack weld shim 105.

FIG. 2A depicts a side view of the device 1, in a closed configuration,for aligning elements, in accordance with the present invention.

FIG. 2B depicts a side view of the device 1, in an open configuration,for aligning elements, in accordance with the present invention.

FIG. 3 depicts a top view of the device 1 in use for aligning elements,in accordance with the present invention. Referring to FIGS. 1-3, thealignment head 20 further comprises: an upper jaw 21, a lower jaw 22,and work windows 23.

The jaws 21 and 22 are for holding a first element 36 and a secondelement 37 so as to allow the elements 36 and 37 to be tack weldedtogether. This is accomplished via the jaws 21 and 22 surrounding theelements 36 and 37. Surrounding as used herein is defined as extendingor partially extending on all sides of the first element 36 and thesecond element 37 simultaneously, i.e., encircle; enclosing orconfining, or partially enclosing or partially confining on all sides soas to secure the elements 36 and 37 within the jaws 21 and 22;encompassing or partially encompassing the first element 36 and thesecond element 37; and combinations thereof.

The jaws 21 and 22 are typically constructed of materials including butnot limited to steel, aluminum, iron, ceramic composites, polymercomposites, nano-polymer composites, alloys of the aforementioned, andcombinations thereof. The construction materials, as previouslydescribed, to form the jaws 21 and 22 are not meant to limit the scopeof the materials that may be used in an embodiment of the presentinvention. Any tack weld resistant material as well as weld resistantmaterial having physical and chemical properties to withstandtemperatures and pressures typically generated under the aforementionedconditions can be used thereof in accordance with the device and methodof the present invention.

Tack welding is the fastening or joining of two elements, via at leastone tack weld, by applying heat, sometimes with pressure and sometimeswith an intermediate or filler metal having a high melting point. A tackweld is a small scale weld, generally performed in a sequence, of twoelements. A sequence of tack welds is used to hold, align, or steersegments of elements to be joined. Elements are defined as elbows, 90°elbows, 45° elbows, tees, reducers, flanges, straight pipe, tubing,hand-railing, boiler tube, square tube, bars, structural shapes, andcombinations thereof.

Elements are typically constructed of materials including but notlimited to steel, aluminum, copper, brass, iron, ceramic composites,polymer composites, nano-polymer composites, alloys of theaforementioned, and combinations thereof. The composition of theelements, as previously described, is not meant to limit the scope ofthe types of elements that may be used in an embodiment of the presentinvention. Any element composition having physical and chemicalproperties to withstand temperatures and pressures typically generatedunder welding and tack welding conditions can be used thereof inaccordance with the device and method of the present invention.

In the open configuration (see FIG. 2B), the first element 36 may beinserted into the jaws 21 and 22 of the alignment head 20 along adirectional arrow 30. The second element 37 then may be inserted intothe jaws 21 and 22 along a directional arrow 31. Alternatively, theelements 36 and 37 may be inserted into the jaws along a directionalarrow 33. Furthermore, the elements 36 and 37 may be inserted into thejaws 21 and 22 by any combination of the aforementioned methods.

In the closed configuration (see FIG. 1 & FIG. 2A), the upper jaw 21 andthe lower jaw 22 typically do not meet together, i.e. do not fullysurround the elements 36 and 37. However, the aforementionedconfiguration as previously described, is not meant to limit theconfiguration of the jaws 21 and 22 with the elements 36 and 37. Thejaws 21 and 22 may fully surround the elements 36 and 37 as previouslydefined. The closed configuration is characterized by the jaws 21 and 22locking the elements 36 and 37 within the jaws 21 and 22.

The work windows 23 have multiple uses. The windows 23 allow a user tovisually align the elements 36 and 37 after they have been inserted intothe jaws 21 and 22. The alignment of the elements 36 and 37 typically isperformed with the device 1 in the closed configuration. The alignmentof the elements 36 and 37 to each other will be locked in place whilstin the closed position. The windows 23 also allow the user to view thesetting of a tack weld gap 38 between the elements 36 and 37. Afteraligning the first element 36 and second element 37 to user requiredspecifications, the elements 36 and 37 can be tack welded together viawelding through the work windows 23. The tack welding can be performedusing any of the work windows 23. Typically, the alignment head 20 iscomprised of one to four work windows.

The work windows 23 provide a visual confirmation that a chosen orspecific tack weld gap 38 clearance between the elements 36 and 37 hasbeen achieved, and also allows the user to quantitatively, i.e., measurethe tack weld gap 38 and axial alignment using typical weld gap 38 andaxial alignment measuring devices. The work windows 23 also allow theuser to inscribe or mark into the elements 36 and 37, in the vicinity ofthe tack weld, any specifications of the tack weld or information that auser may wish to convey about the tack weld.

FIG. 4A is a perspective view of an alignment element 60 of the device1, in accordance with present invention.

FIG. 4B is a side perspective view of the alignment element 60 of thedevice 1, in accordance with the present invention.

FIG. 4C is a perspective view of a second embodiment of the alignmentelement 60 of the device 1, in accordance with the present invention.

FIG. 4D is a side perspective view of a second embodiment of thealignment element 60 of the device 1, in accordance with the presentinvention.

FIG. 4E is a perspective view of a third embodiment of the alignmentelement 60 of the device 1, in accordance with the present invention.

FIG. 4F is a side perspective view of the third embodiment of thealignment element 60 of the device 1, in accordance with the presentinvention. Referring to FIGS. 1-4F; the alignment element 60 comprise analignment element rod 64, a ball and socket joint 65, an alignmentelement body 66, an alignment element contact area 61, and a ball 67.The alignment element 60 is used to precisely and accurately axiallyalign the elements 36 and 37 within the alignment head 20.

The alignment element body 66 is a shoe, pad, a physical body, device,and the like used to secure the first element 36 and the second element37 within the alignment head 20. The alignment element contact area 61is a distinguishable extent of the surface of the alignment element 60which makes contact with the elements 36 and 37, and secures theelements 36 and 37 within the jaws 21 and 22. The area 61 may be asurface comprising of teeth, pads, irregular projections, regularprojections, grooved recesses, micro-teeth, micro-pads,micro-projections, and the like. The area 61 further may have coatingsof the aforementioned on the area 61. The contact area 61 is generallyarcuate shaped, as indicated by arrow 62.

The alignment element rod 64 is used to control movement of thealignment element body 66. The element rod 64 is operably connected tothe ball 67 which fits into the ball and socket joint 65 of the elementbody 66. Adjustment of the element rod 64 in one direction, for exampleturning of the element rod 64 clockwise, results in the element body 66moving towards the elements 36 and/or 37. As the element rod 64 isfurther adjusted, the element body 66 eventually will contact theelements 36 and/or 37 resulting in the axial movement of the elements 36and/or 37.

Adjustment of the element rod 64 in the opposite direction, for exampleturning of the element rod 64 counter-clockwise, results in the elementbody 66 moving away from the elements 36 and/or 37. As the element rod64 is further adjusted, the element body 66 eventually will lose contactwith the elements 36 and/or 37. The alignment body 66 has a range ofmovement from about +¼ inch to about −¼ of an inch.

Typically, the alignment elements 60 are evenly spaced around thealignment head 20 thus allowing for adjustment of the elements 36 and 37in two axis. Adjustment of the elements 36 and 37 along the third axisis performed by hand. The device 1, via the alignment elements 60, isable to axially aligning the elements 36 and 37 in along three differentaxis.

The connection with the ball 67 of the alignment element rod 64 and, theball and socket joint 65 may be permanent, i.e. an integral attachment,or removably attachable with the joint 65 thus allowing varying sizealignment elements 60 to be used with the device 1. Furthermore, thealignment element 60 may be integrally attached to the alignment head 20or it may be non-integrally attached to the alignment head via a wingnut, a square nut, flanges, clips, and the like.

The alignment element 60 is constructed of materials including but notlimited to steel, aluminum, iron, copper, brass, ceramic composites,polymer composites, nano-polymer composites, alloys of theaforementioned, and combinations thereof. The construction materials, aspreviously described, to form the element 60 are not meant to limit thescope of the materials that may be used in an embodiment of the presentinvention. Any tack weld resistant material having physical and chemicalproperties to withstand temperatures and pressures typically generatedunder tack welding conditions can be used to form the alignment element60 thereof in accordance with the device and method of the presentinvention.

Referring to FIGS. 1-3, a pressure mechanism 70 of the device 1, inaccordance with the present invention, may comprise: a torsion spring71, a ratchet 72, a pawl 73, a trigger release 74, a tension control pin75, a bolt 76, and a nut 77. The pressure mechanism 70 allows the userto provide a selectable pressure to the jaws 21, 22 and the pipeelements 36 and 37 held therein. Typically the pressure selected lies ina range from about 0 Pounds per Square Inch (PSI) to about 2,500 PSI.Further, the design is such that the pressure mechanism 70 can readilybe released so as to remove all pressure from the pipe elements and/orto adjust the pressure applied to a different (i.e., greater or less)pressure.

The mechanism 70 includes a torsion spring mechanism which consists of atorsion spring 71 for creating tension to the pawl 73 that engages theteeth of the ratchet 72, permitting motion in one direction with a quickrelease for motion in the opposite direction. Furthermore, the mechanism70 allows for pressure to be created and directed outwardly to theuser's hand via the handles 51 and 52. This provides for a greater feelfor and ease in handling the device 1 during axial alignment of theelements 37 and 37 as well as during tack welding.

The pressure mechanism 70, as previously described, is not meant tolimit the scope of pressure mechanism that may be used in an embodimentof the present invention.

Alternative examples of pressure mechanisms that can be use thereofinclude but are not limited to any type of pawl and ratchet mechanism,and the like. Any pressure mechanism that can produce pressures used toalign and secure pipe elements during tack welding conditions can beused thereof in accordance with the device and method of the presentinvention.

Referring to FIGS. 1, 2A, and 2B the handle 50 comprises: an upper arm51 and a lower arm 52. The upper arm 51 is connected to the lower jaw 22and the lower arm 52 is connected to the upper jaw 21. The arms 51 and52 are so designed such as to allow a user to hold the device 1 with onehand and to selectively apply pressure, via the pressure mechanism 70,while manipulating the elements 36 and 37 with the other hand as well asperforming tack welding and related tasks to the elements 36 and 37.Typically the handle 50 is from about 6 inches to about 9 inches inlength. This distance may or may not include the pressure mechanism 70in the final measurement.

Typically, the alignment head 20, the pressure mechanism 70, and thehandle 50 of the device 1 are configured as one piece and not removablyattachable from one another. The aforementioned configuration, aspreviously described, is not meant to limit the scope of the presentinvention. Alternatively, it can be envisioned where the alignment headsare of differing sizes such as ¼″, ½″, ¾″, 1″, 1¼″ . . . up to 8″ outerdiameter (O.D.) may be reversibly attachable from the handle 50 and/orthe pressure mechanism 70. The characteristic of having an alignmenthead 20 that is reversibly attachable allows for the use of the onehandle 50 and one pressure mechanism 70 with a wide variety of differentsized alignment heads for aligning and tack welding elements 36 and 37of varying sizes.

Typically, an area on the pressure mechanism 70 between the mechanism 70and the jaws 21 and 22 exists where the alignment head 20 is removablyattached to or from the mechanism 70. The means of removable attachmentinclude but are not limited to a hinge, a snap-fit bolt and lock, ascrew-in bolt and lock, a sliding bolt and lock, and combinationsthereof.

Alternatively, the area for removable attachment of the alignment head20 may exist between the pressure mechanism 70 and the handle 50. Thepressure mechanism 70 is may be integrally attached to the alignmenthead 20. Thus, the alignment head 20 having the pressure mechanism 70integrally attached to the head 20 can be removably attached to thehandle 50. The means of removable attachment include but are not limitedto a hinge, a snap-fit bolt and lock, a screw-in bolt and lock, asliding bolt and lock, and combinations thereof.

FIG. 5 is a perspective view of the tack weld shim 105 of the device 1,in accordance with the present invention. Referring to FIGS. 1, 3 and 5,the tack weld shim 105 comprises: a shim end 106, a shaft 107, and anadjustment head 108. The tack shim 105 is used to set the tack weld gap38 between elements. The adjustment head 108 is used to lower or toraise the entire tack shim 105. Typically this is accomplished viaturning of the head 108 clockwise or counter-clockwise causing movementof the tack shim 105 toward or away from the tack shim 105.Alternatively, the head 108 may be pushed or pulled to cause movement ofthe tack shim 105. The methods of adjusting the tack shim 105, aspreviously described, are not meant to limit the scope of the methodsthat may be used in an embodiment of the present invention. Any methodor device that allows for controlled movement of the tack shim 105required under tack welding conditions or pre-tack weld conditions canbe used thereof in accordance with the device and method of the presentinvention.

The shaft 107 extends through the alignment head 20 and typically isthreaded to allow a twisting or rotating motion as described above.Alternatively though, the shaft may be configured in any way such as toallow movement of the shim 105 within the alignment head 20 and withinthe tack weld gap 38. For example, the shaft 107 may be notched,graduated, demarcated, and the like to allow controlled movement of theshim 105 into the tack weld gap 38.

The shim end 106 is the portion of the tack shim 105 that extends intothe tack weld gap 38. The end 106 is typically tapered to allow easyremoval of the shim 105 from the weld gap 38 after tack welding has beperformed. The end 106 also may be coated with materials including butnot limited to ceramics, nano-composites, polymer composites,nano-polymer composites, alloys of the aforementioned, and combinationsthereof to further enhance the ease of removal of the tack shim 105 fromthe weld gap 38 after tack welding has been performed.

The end 106 typically is conical in shape but may be cylindrical,trapezoidal, frustro-conical, and combinations thereof. Any shape of theend 106 that can provide and maintain a pre-selected tack weld gap 38between elements under tack welding conditions or pre-tack weldconditions used as well as allowing for ease of removal from the tackweld gap 38 after tack welding can be used thereof in accordance withthe device and method of the present invention.

Referring to FIGS. 1-5, in use of the device 1 in accordance with thepresent invention, a user adjusts the device 1 having an integratedalignment head 20 to an open configuration (see FIG. 2B) by releasingthe pressure mechanism 70. In this example the pressure mechanism 70 isa torsion spring mechanism, and the elements 36 and 37 are straightpipes and shall be referred herein as pipes 36 and 37. The jaws 21 and22 are opened to provide a clearance wide enough for the pipes 36 and 37to be inserted or slipped into the jaws 21 and 22 along the directionalarrows 30 and 31 respectively or along the directional arrow 33. Anytimeduring the insertion step, the alignment elements 60 can be adjusted,using the alignment element rod 64, also to allow maximum clearance forinsertion of the straight pipes 36 and 37.

The pipes 36 and 37 then are inserted until the edges of the pipes 36and 37 are in the vicinity of each other and can be viewed in the tackweld window 33. Pressure is applied to the pipes 36 and 37 via thepressure mechanism 70 to loosely secure the pipes 36 and 37 within thejaws 21 and 22, and more specifically via the alignment element bodies66 of the alignment elements 60. The alignment element rods 64 are thenadjusted to further apply pressure to the pipes 36 and 37; to secure thepipes 36 and 37 within the alignment head 20; and to axially align thepipes 36 and 37.

The method of applying pressure, securing, and axially aligning thestraight pipes 36 and 37 is an iterative one. The method is repeated asmany times as necessary to accurately and precisely align the pipes 36and 37 with each other for tack welding and other welding tasks.Furthermore, applying pressure, securing, and axially aligning the pipes36 and 37 can be done in any order or in any combination. For example, auser can first secure the pipes 36 and 37 using the alignment elements60 before using the pressure mechanism 70 to lock the pipe elements 36and 37 in place.

Having accurately and precisely aligned the straight pipes 36 and 37,the tack weld gap 38 typically then is set using the tack weld gap shim105. The tack weld shim end 106 of the tack shim 105 is inserted betweenthe straight pipes 36 and 37 via the adjustment head 108. In thisexample, the tack shim 106 comprises a threaded shaft 107 and a conicalend 106 that is demarcated. The head 108 is turned or rotated in aclockwise direction causing the shim 105 and more specifically theconical end 106 to move towards/into the tack weld gap 38. In thisexample, each demarcation is equivalent to 4 mm of space between thepipe elements 36 and 37. Inserting the end 106 of the tack shim 105 tothe 4^(th) demarcation is equivalent to setting the tack weld gap 38 to16 mm.

Alternatively, each demarcation could be equivalent to 1 mm, 2 mm, 3 mmor any unit of distance typically used for tack weld gaps 38 and tackwelding conditions. The tack weld gap 38 can be set from about ⅛ inch toabout ⅕ inch. After having set the tack weld gap 38, the user then maytack weld the pipe elements 36 and 37 knowing that the straight pipes 36and 37 have been accurately and precisely aligned and the tack weld gap38 set per the user's requirement. The device 1 containing the pipes 36and 37, axially aligned and having a chosen tack weld gap 38, is held inone hand while the other hand is used to hold and operate a weldingtorch for subsequent tack welding.

After tack welding is completed, the user removes the tack weld shims105 from the tack weld gap 38. The configuration of the shim end 106 isconducive for easy removal. The pipes 36 and 37 exert significantpressure on the shim end 106 due to cooling of the tack weld and aresultant contraction of the tack weld. The conical shape of the shimend 106 allows the user to easily remove the tack weld shim 105 from theshim gap 38. Any tack weld shim 105 having concial, cylindrical,trapezoidal, frustro-conical, and combinations thereof or havingcoatings with materials including but not limited to ceramics,nano-composites, polymer composites, nano-polymer composites, alloys ofthe aforementioned can be used thereof in accordance with the device andmethod of the present invention.

Typically, a user may axially align and tack weld elements having aparticular diameter with the alignment device 1 appropriately sized towork with the aforementioned pipes. Alternatively, a user may axiallyalign and tack weld elements using an aligning device having anon-integrally attached alignment head, i.e., a reversibly attachablehead for surrounding, securing, and axially aligning the elements.

In use of an aligning device having a reversibly attachable head, a userassembles the device by first attaching the upper jaw and the lower jawof the alignment head to an area on the pressure mechanism between themechanism and the alignment head. The means of removable attachmentinclude but are not limited to a hinge, a snap-fit bolt and lock, ascrew-in bolt and lock, a sliding bolt and lock, and combinationsthereof. After the alignment head has been securely attached to thepressure mechanism, the device is ready to use for aligning pipeelements as described in the aforementioned example.

Alternatively, the area for removable attachment of the alignment headmay exist between the pressure mechanism and the handle. The pressuremechanism is typically integrally attached to the alignment head underthis example but necessarily so. Thus, the alignment head having thepressure mechanism integrally attached to the head can be removablyattached to the handle. The means of removable attachment include butare not limited to a hinge, a snap-fit bolt and lock, a screw-in boltand lock, a sliding bolt and lock, and combinations thereof.

In this example the pressure mechanism is a torsion spring mechanism,and the pipe elements are straight pipes. The jaws and are opened toprovide a clearance wide enough for the straight pipes to be inserted orslipped into the jaws. Anytime during the insertion step, the alignmentelements can be adjusted, using the alignment element rod, also to allowmaximum clearance for insertion of the straight pipes.

The straight pipes then are inserted until the ends of the pipes are inthe vicinity of each other and can be viewed in the tack weld window.Pressure is applied to the pipes via the pressure mechanism to looselysecure the pipes within the jaws, and more specifically via thealignment element bodies of the alignment elements. The alignmentelement rods are then adjusted to further apply pressure to the pipes;to secure the pipes within the alignment head; and to axially align thepipes.

The method of applying pressure, securing, and axially aligning thestraight pipes is an iterative one. The method is repeated as many timesas necessary to accurately and precisely align the pipes with each otherfor tack welding and other welding tasks. Furthermore, applyingpressure, securing, and axially aligning the pipes can be done in anyorder or in any combination. For example, a user can first secure thepipes using the alignment elements before using the pressure mechanismto lock the pipe elements in place.

Having accurately and precisely aligned the straight pipes, the tackweld gap typically then is set using the tack weld gap shim. The tackweld shim end of the tack shim is inserted between the straight pipesvia the adjustment head. In this example, the tack shim comprises athreaded shaft and a conical end that is demarcated. The head is turnedor rotated in a clockwise direction causing the shim and morespecifically the conical end to move towards/into the tack weld gap. Inthis example, each demarcation is equivalent to 4 mm of space betweenthe pipe elements. Inserting the shim end of the tack shim to the 4^(th)demarcation is equivalent to setting the tack weld gap to 16 mm.

Alternatively, each demarcation could be equivalent to 1 mm, 2 mm, 3 mmor any unit of distance typically used for tack weld gaps and tackwelding conditions. The tack weld gap can be set from about ⅛ inch toabout ½ inch. After having set the tack weld gap, the user then may tackweld the pipe elements knowing that the straight pipes have beenaccurately and precisely aligned and the tack weld gap set per theuser's requirement. The device containing the pipes, axially aligned andhaving a chosen tack weld gap, is held in one hand while the other handis used to hold and operate a welding torch for subsequent tack welding.

After tack welding is completed, the user removes the tack weld shimsfrom the tack weld gap. The configuration of the shim end is conducivefor easy removal. The straight pipes exert significant pressure on theshim end due to cooling of the tack weld and a resultant contraction ofthe tack weld. The conical shape of the shim end allows the user toeasily remove the tack weld shim from the shim gap. Any tack weld shimend having concial, cylindrical, trapezoidal, frustro-conical, andcombinations thereof or having coatings with materials including but notlimited to ceramics, nano-composites, polymer composites, nano-polymercomposites, alloys of the aforementioned can be used thereof inaccordance with the device and method of the present invention. The userthen may disassemble the device by removing the alignment head from thearea on the pressure mechanism in which the alignment head was attached.

Alternatively, a user may axially align and tack weld elements using analigning device 1 having non-integrally attached alignment elements 60,i.e., reversibly attachable alignment elements 60 for securing andaxially aligning pipe elements. Referring to FIGS. 1-5, in use of thedevice 1 in accordance with the present invention, a user attaches thereversibly attachable alignment elements 60 to the alignment head 20 ofthe device 1. The alignment elements 60 may be secured to the alignmenthead 20 via a wing nut, a square nut, flanges, clips, and the like.

The user then adjusts the device 1 with the alignment elements 60attached to the alignment head 20 to an open configuration (see FIG. 2B)by releasing the pressure mechanism 70. In this example the pressuremechanism 70 is a torsion spring mechanism, and the pipe elements 36 and37 are straight pipes.

The jaws 21 and 22 are opened to provide a clearance wide enough for thestraight pipes 36 and 37 to be inserted or slipped into the jaws 21 and22 along the directional arrows 30 and 31 respectively or along thedirectional arrow 33. Anytime during the insertion step, the alignmentelements 60 can be adjusted, using the alignment element rod 64, also toallow maximum clearance for insertion of the straight pipes 36 and 37.

The straight pipes 36 and 37 then are inserted until the edges of thepipes 36 and 37 are in the vicinity of each other and can be viewed inthe tack weld window 33. Pressure is applied to the pipes 36 and 37 viathe pressure mechanism 70 to loosely secure the pipes 36 and 37 withinthe jaws 21 and 22, and more specifically via the alignment elementbodies 66 of the alignment elements 60. The alignment element rods 64are then adjusted to further apply pressure to the pipes 36 and 37; tosecure the pipes 36 and 37 within the alignment head 20; and to axiallyalign the pipes 36 and 37.

The method of applying pressure, securing, and axially aligning thestraight pipes 36 and 37 is an iterative one. The method is repeated asmany times as necessary to accurately and precisely align the pipes 36and 37 with each other for tack welding and other welding tasks.Furthermore, applying pressure, securing, and axially aligning the pipes36 and 37 can be done in any order or in any combination. For example, auser can first secure the pipes 36 and 37 using the alignment elements60 before using the pressure mechanism 70 to lock the pipe elements 36and 37 in place.

Having accurately and precisely aligned the straight pipes 36 and 37,the tack weld gap 38 typically then is set using the tack weld gap shim105. The tack weld shim end 106 of the tack shim 105 is inserted betweenthe straight pipes 36 and 37 via the adjustment head 108. In thisexample, the tack shim 106 comprises a threaded shaft 107 and a conicalend 106 that is demarcated. The head 108 is turned or rotated in aclockwise direction causing the shim 105 and more specifically theconical end 106 to move towards/into the tack weld gap 38. In thisexample, each demarcation is equivalent to 4 mm of space between thepipe elements 36 and 37. Inserting the end 106 of the tack shim 105 tothe 4^(th) demarcation is equivalent to setting the tack weld gap 38 to16 mm.

Alternatively, each demarcation could be equivalent to 1 mm, 2 mm, 3 mmor any unit of distance typically used for tack weld gaps 38 and tackwelding conditions. The tack weld gap 38 can be set from about ⅛ inch toabout ½ inch. After having set the tack weld gap 38, the user then maytack weld the pipe elements 36 and 37 knowing that the straight pipes 36and 37 have been accurately and precisely aligned and the tack weld gap38 set per the user's requirement. The device 1 containing the pipes 36and 37, axially aligned and having a chosen tack weld gap 38, is held inone hand while the other hand is used to hold and operate a weldingtorch for subsequent tack welding.

After tack welding is completed, the user removes the tack weld shims105 from the tack weld gap 38. The configuration of the shim end 106 isconducive for easy removal. The straight pipes 36 and 37 exertsignificant pressure on the shim end 106 due to cooling of the tack weldand a resultant contraction of the tack weld. The conical shape of theshim end 106 allows the user to easily remove the tack weld shim 105from the shim gap 38. Any tack weld shim 105 having concial,cylindrical, trapezoidal, frustro-conical, and combinations thereof orhaving coatings with materials including but not limited to ceramics,nano-composites, polymer composites, nano-polymer composites, alloys ofthe aforementioned can be used thereof in accordance with the device andmethod of the present invention. The user then may disassemble thedevice 1 by removing the alignment elements 60 from the alignment head20.

As depicted clearly in the drawings, an aligning device 1 includes analignment head 20 (see FIGS. 1-3). The alignment head 20 is configuredto be removably secured (see, for example, FIG. 2A) proximate an end ofa first structural element, such as element 36 (see FIGS. 2A-3), to bealigned and connected. For example, embodiments of the device 1 may besecured onto the pipe element 36, inter alia, by a user throughsqueezing the handle 50, as optionally facilitated by a pressuremechanism 70, so that portions of the device 1 securely engage thestructural pipe element 36. A user may remove the head 20 from itssecured position on the structural pipe element 36, by unsqueezing orotherwise disengaging the handle 50 and/or pressure mechanism 70.Moreover, the aligning device 1 includes at least one alignment element60 attached to the alignment head 20. The at least one alignment element60 has a plunging body 66 (see FIGS. 1-2B and 4A-4F). Additionally, theplunging alignment element body 66 is extendable from the alignment head20 to non-rotatably engage an end of a second structural element, suchas element 37, to be aligned and connected (see FIGS. 1-3). The plungingbody 66 is rotatably secured because of its shape. As clearly shown, thegenerally polygonal shape of the plunging alignment element body 66prevents the body 66 from rotating as it operably plunges with respectto the alignment head 20 (see FIG. 1, which shows the rectangular endsof the plunging bodies 66 of the alignment elements 60 as partiallyprotruding from the alignment head 20; see also the cross-sectionalviews of FIGS. 2A-B, which depict no gap or space between the plungingalignment element body 66 and the alignment head 20, thereforephysically prohibiting rotational movement thereof).

In addition, embodiments of an aligning device 1 include a drive member,such as element rod 64 (see FIGS. 1-4F), wherein the drive member rod 64contacts the plunging alignment element body 66 to move the plungingbody 66 without rotating the plunging body 66. The plunging body 66 isrotationally fixed with relation to the alignment head 20. As depictedin FIGS. 2A-B and in relation to FIGS. 4A-4F, the drive member rod 64includes an integral ball 67 at one end that operates with a ball socket65 of the plunging alignment element body 66. The drive member rod 64may be threaded, and thus may threadably operate with an alignmentelement 60 of an alignment head 20. Accordingly, as the drive member rod64 is threadably rotated it may advance with respect to the alignmenthead 20. However, during threaded advancement, the ball 67 of the drivemember rod 64 merely twists or rotates inside the ball socket 65 of theplunging alignment element body 66. Therefore, the advancing drivemember rod 64 may operate on the plunging alignment element body 66 topush, plunge, or otherwise advance the plunging body 66 with respect tothe alignment head 20, without transferring substantial rotation forcesto the plunging body 66. The polygonal shape of the plunging body alsoprevents rotation. Consequently, the plunging body 66 may non-rotatablyengage a structural element, such as element 36 and/or 37, to be alignedand connected. Non-rotatable contact between the plunging alignmentelement body 66 and the structural element 36 and/or 37 to be aligned orconnected is advantageous because alignment movements of the variouselements 36, 37 as worked upon by the aligning device 1, may be moreprecisely controlled and predicted. Rotational contact is undesirablebecause it may tend to skew orientation of the elements 36, 37 as theelements 36, 37 are aligned.

Known aligning devices of the prior art provide ball bearings or otherimplements that allow plunging members to rotate separately from drivingmembers. However, standard aligning devices do not prevent plungingmembers from rotating. Thus, prior art aligning devices suffer becauseunder a load the typical rotationally separate plunging members lock upwith the corresponding drive members or otherwise become physicallyengaged rotationally with the with the drive members. Hence, the typicalplunging members rotate with the drive member when under a load while incontact with a structural element to be aligned, thereby distorting thedesired orientation of a structural element by transferring undesirablerotational force to the structural element. In contrast to the knownart, embodiments of an aligning device 1 prevent rotation of theplunging member as it is driven and facilitate advantageousnon-rotational contact between plunging bodies 66 of the device 1 andthe elements 36, 37 to be aligned and connected.

With reference to FIG. 6, an embodiment of a structural connectionaligning device 4 is depicted. The structural connection aligning device4 may include an alignment head 420 configured to receive an end of astructural element, such as a first pipe 36, and an end of a structuralelement, such as a second pipe 37 (shown in FIG. 3). Moreover, thestructural connection aligning device 4 may include an alignment element460 attached to the alignment head 420. The aligning device 4 mayinclude a plurality of alignment elements 460 attached to the alignmenthead 420. Still further, the alignment head 420 may be removablyattached to a handle 450 and/or a pressure mechanism 470. As depicted,the pressure mechanism is located proximate the alignment head 20.However, those in the art should appreciate that the pressure mechanism470 may be located anywhere along handle 450, in order to obtain adesired amount of mechanical advantage. Similarly the pressure mechanism70 of aligning device 1, shown in FIGS. 1-3, may also be locatedanywhere along handle 50 to achieve a desired mechanical advantage.

The alignment head 420 may be configured to be removably positionedproximate the structural elements 36 and/or 37. For example, thealignment head 420 may be configured to at least partially encircle astructural element such as a pipe 36, 37. Additionally, the handle 450may operate to move the head 420 to at least partially encircle the pipeelement 36 and/or 37 and the head 420 may be configured to open or closeas the handle 450 is squeezed closed or spread open. The alignment head420 may further include an upper jaw 421 and a lower jaw 422. The jaws421 and 422 may assist in holding a first pipe element 36 and a secondpipe element 37 so as to allow the pipe elements 36 and 37 to be tackwelded together. This is accomplished via the jaws 421 and 422 at leastpartially surrounding the pipe elements 36 and 37. The upper jaw 421 andthe lower jaw 422 may not touch or meet together, i.e. the jaws 421, 422may not fully surround the structural elements 36 and 37. However, thejaws 421 and 422 may fully surround the pipe elements 36 and 37 when thejaws 421 and 422 are located in a closed position. Hence, the head maybe removably, but securely positioned proximate the ends of thestructural pipe elements 36 and/or 37.

A structural connection aligning device 4 may include work windows, suchas work windows 23 shown in FIGS. 1 and 3. The work windows may beoperable with the head 420 and may have multiple uses. The windows 23allow a user to visually align the structural elements 36 and 37 afterthey have been inserted into the jaws 421 and 422. The alignment of thestructural elements 36 and 37 typically is performed with the structuralconnection aligning device 4 in a closed configuration (similar to theclosed position of aligning device 1 shown in FIG. 2A). The windows 23also allow a user to view the setting of a tack weld gap 38 between thestructural pipe elements 36 and 37. After aligning the first pipeelement 36 and second pipe element 37, the pipe elements 36 and 37 canbe tack welded together via welding through the work windows 23. Thetack welding can be performed using any of the work windows 23.Typically, the alignment head 420 includes one to four work windows.

Referring further to the drawings, FIG. 7A depicts a blown-up partialsectional view of an embodiment of an alignment element 460 operablewith an embodiment of an alignment head 420 to engage a structuralelement 36. The alignment element 460 includes a plunging body 466, acartridge 468, and a drive member 464. The plunging body 466 is at leastpartially housed by and axially movable within the cartridge 468. Thedrive member 464 contacts the plunging body 466 to move the plungingbody 466. In addition, the plunging body 466 may be extendable from thealignment head 420 to non-rotatably engage the pipe element 36 when thealignment head 420 is at least partially encircled about the pipeelement 36. The plunging body 466 is rotatably secured and can notrotate. The drive member 466 of the alignment element 460 may beoperable with the cartridge 468, such that the drive member 464 maycontact the plunging body 466 to move, plunge, advance or otherwiseextend the plunging body 466 without transferring significant rotationalforce to the plunging body 466.

The alignment element 460 may further comprise a spring 469 contactingthe plunging body 466 and operable to exert a force against the plungingbody 466 causing the plunging body 466 to remain in contact with thedrive member 464. The spring 469 also contacts the alignment head 420,the spring 469 being positioned between the plunging body 466 and thealignment head 420. In such a position, the spring 469 may act to keepthe plunging body 466 in contact with the drive member 464. Moreover,contact between the plunging body 466 and the drive member 464 is atleast partially facilitated by the positioning of the spring 469 betweenthe plunging body 466 and the head 420 to exert force upon the plungingbody 466 in a direction toward the drive member 464.

The cartridge 468 may be removably attached to the head 420. As such thecartridge 468 may include exterior threads 423 configured to threadablymate with internal threads 424 of a hole 427 corresponding an alignmentelement 460 mounting location of the alignment head 420. The hole 427may not extend all the way through the head 420 and accordingly may havea bottom floor to which the cartridge may abut when fully threaded intothe hole 427. However, it should be recognized that the hole 427 mayextend completely through a jaw 421, 422 of the alignment head 420.

Referring further to the drawings, FIG. 7B depicts a blown-up partialsectional view of another embodiment of an alignment element 465. Thealignment element 465 may be configured to be pressed to fit into a hole428 of an alignment head 420. The hole 428 may have substantially smoothedges that may be fashioned for a tight tolerance fit with correspondingsmooth outer edges of an embodiment of a cartridge 463. Accordingly, thealignment element 465 may be press fit into position on the alignmenthead 420. To securely retain the alignment element 465 in appropriateposition a pin or other securing member 425 may be placed to interferewith the possible retractability of the cartridge 463 after is has beenappropriately press fit into the hole 428 of the alignment head 420. Thepin or other securing member may be removably positioned into thealignment head 410 and may be in physical contact with the cartridge463.

Referring to both FIGS. 7A and 7B, the driver member 464 may be ahex-head jack screw that may be threadably inserted through the top ofthe cartridge 468, 463. Thus the drive member 464 may operate with thecartridge 468, 463 to advance downward toward the plunging body 466 whenthe drive member 464 is rotated by a tool adapted to turn it; a toolsuch as an Allen wrench matching the dimension of the hex-head. Those inthe art should recognize the various driver heads (flat head, Phillip'shead, square head) may be employed to help turn the drive member 464.Moreover, the drive member 464 may be a rod or other element fashionedwith wing-nut-type fixtures that a user may easily grasp to help turnthe drive member 464. The plunging body 466 of the alignment element460, 465 is extended toward the structural element 36, 37 by contactforces exerted by the drive member 464 of the alignment element 460 465.Hence, as the drive member 464 threadably advances downward, it pusheson the plunging body 466 extending it downward as well.

With continued reference to the drawings, FIGS. 8A-C respectively depictperspective, end and side views of an embodiment of a plunging body 466.The plunging body 466 may include a first end 482 and a correspondingopposite second end 484. The first end 482 of the plunging body 466 mayinclude a connection structure contact area 481. The alignment element460 structure contact area 481 is a distinguishable extent of thesurface of the first end 482 of the alignment element 460 which makescontact with the structural elements 36 and 37, and secures thestructural elements 36 and 37 within the jaws 421 and 422. Theconnection structure contact area 481 may be a surface comprising ofteeth, pads, irregular projections, regular projections, groovedrecesses, micro-teeth, micro-pads, micro-projections, knurling, and thelike. In addition, the connection structure contact area 481 further mayhave coatings of the aforementioned on the area 481. The structuralconfiguration of the connection structure contact area 481 should bearranged to efficiently and effectively engage and hold fast against astructural element, such as a pipe 36, 37 when the connection structurecontact area 481 contacts the structural element 36, 37. Hence, thecontact area 481 may be arcuate to and contoured to match the outercurvature of the pipe 36, 37. The matched contour of the contact area481 of the first end 482 contributes to the prevention of rotation ofthe plunging body 466 because of greater contact and increased frictionwith the pipe 36, 37. The contact area should help prevent rotation ofthe plunging member 466 when engaged with any type of structural elementto be aligned. Extending substantially between the first end 482 and thesecond end 484 of the plunging body 466 may be an elongated plungingbody portion 486.

The second end 484 of the plunging body 466 may include an enlarged headmember 488. Then enlarged head member may include a spring contactsurface 487 configured to engage a spring 469 (see FIGS. 7A-B) andreceive spring 469 forces as applied to the plunging body 466. Thesecond end 484 of the plunging body 466 is configured to engage thedrive member 464 as the drive member 464 moves and drives the plungingbody 466. Accordingly, where drive member embodiments may be moved oradvanced via threadable rotation, it is advantageous to have the secondend of the plunging body 466 designed to minimize friction and transferof rotational forces from the drive member 464. The primary interactionof the drive member 464 is to drive the plunging body 466 axially.Hence, an axis of the drive member 464 and an axis of the plunging body466 may be co-aligned. Thus, the dynamic contact between the drivemember 464 and the plunging body 466 may not transfer substantialrotational forces from the drive member 464 to the plunging body 466.The plunging body 466 is rotatably secured and can not rotate. Tofurther prevent any ability for the plunging body 466 to turn about acentral axis as a result of rotational forces possibly transferred bythe drive member 464, the plunging body 466 can operate with a key slot489, such as a dimple or other socket-type member designed to receive aball bearing, a pin, a protrusion or any other key member that acts tophysically prevent rotation of the plunging body 466 due to obstructionby the key member. The key member, such as a ball bearing, may beoperable with both the plunging body 466 via key slot 489 and may alsobe operable with a cartridge 468 through a key slot structure 499 on theinterior surface of the cartridge 468. Similar key slot 499 structuringmay also correspond to the cartridge 463.

By way of example, FIGS. 9A-E respectively depict vertical side,perspective, bottom end, top end, and horizontal side views of anembodiment of a cartridge 468 of an embodiment of an alignment element460. The cartridge 468 includes a first end 492 and correspondingopposite second end 494. For practical purposes, the first end 492 maycorrespond to the bottom end of the cartridge 468, or the end of thecartridge 468 oriented toward the alignment head 420 and structuralelements 36, 37. The second end 494 of the cartridge 468 may correspondto the top end of the cartridge 468. Extending from the first end 492into the cartridge 468 may be a generally cylindrical interior hollow498 having a substantially constant diameter. Located on a side of theinterior hollow 498 may be a vertical key slot 499 running parallel to acentral axis of the alignment element 460. The key slot 499 may extendfor the entire length of the hollow. The diameter or cross-section ofthe key slot 499 in the interior hollow 498 of the cartridge 468 shouldcorrespond to the diameter of the dimple key slot 489 of the plungingbody 466. Hence a ball bearing (not shown) may be positioned within thedimple 489 of the plunging body 466 and also within the vertical slot499 of the cartridge 468 to securely retain the plunging body 466 andthe cartridge 468 in non-rotatable relation to each other while stillpermitting linear axial movement of the separate components.Accordingly, the plunging body 466 and cartridge 468 are generallysecured about a central axis of the alignment element 460 so thatneither the plunging body 466 nor the cartridge 468 can substantiallyrotate with respect to the other. Rotation of the plunging body 466 isphysically prevented. Thus, the drive member 464, being operable withthe cartridge 468 of the alignment element 460, may extend the plungingbody 466 without rotating the plunging body 466 with respect to thecartridge 468 or the engaged structural element 36, 37. Because theplunging body 466 does not rotate, but merely extends axially, withrespect to the alignment element 460, the plunging body 466 does nottransfer any rotational forces onto the structural element 36, 37 whenthe plunging body 466 engages and moves the structural element 36, 37during the alignment process.

Extending into the cartridge 468 from the second end 494 of thecartridge 468 may be a threaded hole 493. The threaded hole 493 may beconfigured having a diameter and thread count to receive and operatewith the drive member 464. Therefore, as the drive member 464 isrotated, it may be threadably advanced either toward or away from theplunging body 466 housed at least partially within the interior hollow498 of the cartridge. To further assure that the cartridge 468 does notrotate due to forces exerted on it by the drive member 464, and togenerally retain the cartridge 468 in a desired location andorientation, embodiments of the cartridge 468 may include one or moreflat surfaces 495 located on an elongated outer cartridge portion 496.The flat surface(s) 495 may be operable with a set screw (not shown, butwell known in the art) extending through the alignment head 420 to abutthe flat surface 495. The attachment of the alignment element 460 to thealignment head 420 may be facilitated at least in part by the set screw.Hence, the cartridge 468 may be inserted into the hole 427 of the pipealignment head 420 and threadably advanced until the cartridge 468reaches a location where the set screw extending through a hole (notshown) in the side of the head 420 may contact the flat face 495 of thecartridge 468 and prevent the cartridge 468 from rotating and threadablyadvancing, in either direction any further. Thus the operable employmentof the set screw may serve to secure the cartridge 468, and the plungingbody 466 (due to the associated ball bearing) in a rotationally staticposition with respect to each other and the head 420.

The plunging body 466 of an alignment element 460 may be non-rotabablymoved to contact one of the first structural element, such as a pipe 36,or the second structural element, such as a pipe 37, depending on whichstructural element 36, 37 resides beneath the alignment element 460 whenthe structural element 36, 37 is removably secured proximate thealignment head 420. It should be noted that a plurality of alignmentelements 460 may be included on one alignment head 420 (see FIG. 6).Hence, in an arrangement where a first alignment element 460 contacts afirst structural element 36, at least another alignment element 460 mayalso be simultaneously attached to the head 420, wherein the otheralignment element 460 also includes a plunging body 466 that isconfigured to engage a structural element, such as the second pipe 37,and move the second pipe 37 into alignment with the first pipe element36. The number of alignment elements 460 provided on an alignment headmay correspond to the size of the structural element to be aligned. Forexample, large straight pipe pieces, pipe fittings, beams, or sheets,etc, may include more alignment elements 460 than small pipes, pipefittings, beams, or sheets.

The alignment elements 460, 465 operable with the aligning device 4, mayvary in size and dimension. Furthermore, the alignment element(s) 460,465 may be integrally attached to the alignment head 420 rather thannon-integrally, or removably attached to the alignment head 420. Thealignment element(s) 460, 465 may be constructed of materials includingbut not limited to steel, aluminum, iron, copper, brass, ceramiccomposites, polymer composites, nano-polymer composites, alloys of theaforementioned, and combinations thereof. The construction materials, aspreviously described, to form the alignment element(s) 460, 465 are notmeant to limit the scope of the materials that may be used inembodiments of the present invention. Any tack weld resistant materialhaving physical and chemical properties to withstand temperatures andpressures typically generated under tack welding conditions can be usedto form the pipe alignment element(s) 460, 465 in accordance with thedevice and method of the present invention.

With reference to FIGS. 1-3 and 6-9E, a pressure mechanism 470 may beincluded with the pipe alignment device 4, in accordance withembodiments of the present invention. The pressure mechanism 470 may beoriented anywhere with the handle 450 to provide a desired degree ofmechanical advantage. Additionally, work windows 23 may provide a visualconfirmation that a chosen or specific tack weld gap 38 clearancebetween the pipe elements 36 and 37 has been achieved, and also mayallow the user to quantitatively, i.e., measure the tack weld gap 38 andaxial alignment using typical weld gap 38 and axial alignment measuringdevices. The work windows 23 also allow the user to inscribe or markinto the pipe elements 36 and 37, in the vicinity of the tack weld, anyspecifications of the tack weld or information that a user may wish toconvey about the tack weld. Furthermore, the characteristics of aligningdevice 1 of possibly having an alignment head 20 that is reversiblyattachable also applies to the aligning device 4. Thus the aligningdevice 4 may also allow for the use of one handle 450 and one pressuremechanism 470 with a wide variety of different sized alignment heads 420and/or alignment elements 460, 465 for aligning and tack weldingstructural elements 36 and 37 of varying sizes. Various, pipes, rods,beams, angle-iron, I-beams, L-beams, hand-railings, flats, sheets, orother structures may be aligned for connection by embodiments of analigning device 4.

With continued reference to the drawings, FIGS. 10A-B depict sidesectional views of still another embodiment of an aligning device 5prior to and also following alignment of structural elements 536 and537. As depicted, the structural elements 536 and 537 are two flatsheets of metal. However, those in the art should appreciate thatvarious structural elements, such as pipes, rods, beams, angle-iron,I-beams, L-beams, hand-railings, flats, sheets, or other structures, maybe aligned for connection by embodiments of an aligning device 5. Analigning device 5 may include an alignment head 520. The alignment head520 may include a base 521. The base 521 may be configured to beremovably mounted to a structural element 536 proximate an end of thestructural element 536. Removable mounting may be facilitated by tackwelds 522 a and 522 b that connect the base 521 of the alignment head520 to the structural element 536. The tack welds 522 a-b should besufficient enough to secure the aligning device 5 in appropriateposition of helping the alignment and connection of structural elements536, but should also be provided so as to allow a user to pry and/or popthe welds off once alignment and connection of the structural elements536, 537 has taken place. Other means of connecting the base 521 of thealignment head 520 to the structural element 536 may include magnets,glues, epoxies, bolts and nuts, screws, rivets, hook-and-loop fasteners,clamps, clips, and/or other like connection means.

Referring further to FIGS. 10A-B, embodiments of an aligning device 5may include at least one alignment element 560. The at least onealignment element 560 may be removably attached to the alignment head520. An alignment device 5 may have multiple alignment heads 560. Asdepicted, the alignment element 560 is similar to that shown in FIG. 7A.However, those in the art should appreciate that various embodiments ofalignment elements may operate with an aligning device 5. For instance,the alignment elements 560 may be similar to the alignment element 465shown in FIG. 7B, with corresponding changes to the alignment head 520.Moreover, the alignment elements 560 may be similar to the alignmentelements 60 shown in FIGS. 1-4F, wherein the alignment head 520 may havephysical changes corresponding to the operable attachment of thealignment elements 60 thereto. In every embodiment of an alignmentelement, the plunging body is rotatably secured so that it can notrotate.

An aligning device 5 includes a plunging body 566. The plunging body 566may operate with a drive member 564, such as a screw or other threadedobject. Moreover the plunging body 566 may contact the drive member 564as assisted by a spring 569. Furthermore, the plunging body 566 mayoperate with a cartridge 568 to help orient the plunging body 566 withrespect to the alignment head 520 and facilitate plunging from thealignment head 520.

As depicted in FIG. 10A, the flat structural element 537 is not properlyaligned for connection with the flat structural element 536. Properalignment, with regard to the depicted structural elements 536, 536,means that the end of the structural element 536 is substantiallyco-planar with the end of the structural element 537 as depicted in FIG.10B. Those in the art should appreciate that alignment may consist ofany user-preferred configuration and that proper alignment, as usedherein, is provide for exemplary purposes of demonstrating how analigning device 5, may be utilized to help align structural elements forconnection. Thus, it can be seen that the plunging body 566 may beadvanced by the drive member 564 to work upon the structural element 536and move it into proper alignment. Windows or other means (not shown)may be incorporated into the alignment head 520 to allow a user to weldor otherwise access to two structural elements 536, 537 during orfollowing alignment. Moreover, at tack shim, such as tack shim 105, maybe incorporated into the design to help maintain and appropriate weldgap, such as gap 538.

With still further reference to the drawings, FIG. 11 depicts a sideview of a further embodiment of an aligning device 6, wherein the handle650 is depicted in a range of positions. The depiction is providedmerely to show an illustrative range of movement of the handle 650.Although, other features of the alignment device 6 would move inrelation to the movement of the handle, the movement of such otherfeatures is not provided. The alignment element 660, may be similar tothe alignment element 465 (shown in FIG. 7B). However, the drive member664 (similar to the drive member 464) may be seated within the alignmentelement 660 so that it is not visible in a side view. The spring 669(similar to the spring 469) is also not visible in the side view ofalignment device 6 shown in FIG. 11. The tack shim members 105 arevisible and are operable with the alignment head 620 of the alignmentdevice 6. FIG. 12 depicts a side view of the embodiment of the aligningdevice 6 of FIG. 11. However, for clarity, the device 6 is depictedwithout alignment elements 660 or tack shims 105 being shown. Thedepiction of FIG. 12 reveals one portion of the range of the handle 650of the aligning device 6, wherein the handle 650 resides in a fullyclosed position. In further description of operable movement, FIG. 13depicts a side view of the embodiment of the aligning device 6 of FIG.11 (also without alignment elements 660 or tack shims 105 shown),wherein the handle 650 is depicted in a fully open position allowing anembodiment of structural element 36, such as a pipe, rod, tube, beam orother structure, to be inserted within the alignment head 620.Accordingly, FIG. 14 depicts a side view of the embodiment of thealigning device 6 of FIG. 11, wherein the structural element 36 has beeninserted within the alignment head 620 while the handle 650 is in anopen position.

Embodiments of an aligning device can be used to align structuralelements of various sizes and shapes. For example, and aligning device 6may be configured to facilitate alignment of pipes having variousdiameters ranging from ½ inch to 10 inches. Accordingly the size thealigning device 6 including the alignment head 620 and the handle 650and all other components may vary relative to desired use, such as forsmaller pipes or larger pipes. Furthermore, embodiments of an aligningdevice may be configured to facilitate alignment of angled or bent pipefixtures or connection pieces, square or rectangular tubing, angle iron,channels, flats, I-beams, or other structural members to be aligned andconnected. As such, embodiments of aligning devices may be configured toplace alignment elements, such as elements 660, in close proximity withstructural elements 36 or 37, so that the alignment elements be utilizedto act upon the structural elements 36 or 37 and move them intoalignment with each other. For example, FIG. 15 depicts a side view ofthe embodiment of the aligning device 6 of FIG. 11, wherein thestructural element 36 has been inserted within the alignment head 620while the handle 650 is maneuvered toward a closed position bringing thealignment elements 660 closer to the structural element 36. When thealignment elements 660 have been brought securely into close proximitywith the structural elements 36 or 37 then the alignment elements 660may be made to contact and hold or work upon and move the structuralelements 36 or 37. For instance, FIG. 16 depicts a side view of theembodiment of the aligning device 6 of FIG. 11, wherein the structuralelement 36 has been inserted within the alignment head 620 while thehandle 650 is maneuvered further toward a closed position bringing thealignment elements 660 into contact with the structural element 36. Oncein this position, drive members 664 (not shown) may be manipulated tomove the plunging bodies 666 and thereby move the structural member 36.Similar with the description above, drive members 664 move plungingbodies 666 without rotating plunging bodies 666 so that the plungingbodies 666, as they are in contact with the structural element 36 or 37,do not transfer any rotational force onto the structural elements 36 or37. This is advantageous because alignment movement can be much morereadily controlled and the structural elements 36 and/or 37 may be muchmore effectively secured into proper alignment.

Those in the art should appreciate that the movement of variouscomponents of embodiments of an aligning device may be assisted,enhanced, controlled, or otherwise modified by mechanical, hydraulic,pneumatic, or electric motor means. For example, FIG. 17 depicts a sideview of a still further embodiment of an aligning device 7 having apressure mechanism 770 including a manually activated pawl ratchet 773.Teeth of the pawl ratchet 773 may engage a pin 774, or othercomplimentary structure serving to prevent movement of the handle 750 inan open direction while the pawl ratchet 773 is engaged. The pawlratchet 773 may pivot at a location 775 operable with an arm of thehandle 750. Moreover, a connection member 772 may link the pawl ratchet773 to a release tab 771 that may be operated by a user to disengage thepawl ratchet 773 from the pin 774 and permit opening movement of thehandle 750. Accordingly, a user may operate the aligning device 7 byusing the release tab 771 to disengage the pawl ratchet 773 to allow thehandle 750 to move to an open position so that the alignment head 720may open wide to receive a structural element, such as structuralelement 36 or 37. Then the user may compress the handle 750 so that thealignment elements 760 are moved into close proximity or contact withthe structural element 36 or 37. The closing of the handle 750 may actin conjunction with ratcheting of the pawl ratchet 773 so that thehandle 750 steps securely toward a closed position and facilitates asecure connection with the structural member 36 or 37. When thestructural element 36 and/or 37 has been secured, then the plungingbodies 766 of the alignment elements 760 may be driven by drive members(not visible) to move the structural element 36 and/or 37 into properalignment position.

While the alignment device 7 is shown with a manually operatedmechanical pressure mechanism 770 including a pawl ratchet 773, those inthe art should recognize that other devices or implements may beincluded in an alignment device embodiment to assist, enhance, control,or otherwise modify movement of an alignment head into closer proximitywith a structural element, such as element 36 and/or 37 to be aligned.For example, a manually actuated double pawl ratchet may be includedwith a pressure mechanism, such as pressure mechanism 770 of aligningdevice 7. Moreover, a worm gear thread device may be provide and may bemanually or electrically operable. Furthermore, a hydraulic pump-assistactivation mechanism may be included to help a user close the handle 750or otherwise move an alignment head into closer proximity with astructural element, such as element 36 and/or 37, to be aligned. Stillfurther, an air cylinder compressed-air-activation mechanism may beprovided to add or retain pressure during operation of the aligningdevice 7 and otherwise secure a structural element into proper alignmentposition. The various means for movement assistance may be configured tofunction in correlation with the aspects of aligning device embodiments.

An embodiment of a pipe aligning method is described with relation toFIGS. 1-17. One methodological step of structural connection aligningmay include providing an end of a first structural element 36 and an endof a second structural element 37. Another methodological step mayinclude providing an aligning device 1, 4, 5, 6, 7 including arespective head 20, 420, 520, 620, 720 configured to be removablypositioned proximate the end of the first structural element 36; thealigning device 1, 4, 5, 6, 7 further including an alignment element 60,460, 465, 560, 660, 760 respectively attached to the head 20, 420, 520,620, 720; the alignment element 60, 460, 465, 560, 660, 760 having arespective plunging body 66, 466, 566, 666, 766 extendable from the head20, 420, 520, 620, 720. A further methodological step of structuralconnection aligning may include extending the plunging body 66, 466,566, 666, 766 from the head 20, 420, 520, 620, 720 to non-rotatablyengage the second structural element 37 because the plunging body 66,466, 566, 666, 766 is prevented from rotating. Moreover, a still furthermethodological step may include moving the non-rotatably engaged secondstructural element 37 via extension of the plunging body 66, 466, 566,666, 766 to align the end of the second structural element 37 with theend of the first structural element 36.

Further structural connection aligning methodology may include theplunging body 66, 466, 566, 666, 766 of the respective alignment element60, 460, 465, 560, 660, 760 being extended by contact forces exerted bya drive member 64, 464, 564, (664 and 764 not shown in side view, butsimilar in structure and functionality) of the alignment element 60,460, 465, 560, 660, 760 such that the drive member 64, 464, 564, 664,764 (all drive members optionally being operable with a cartridge 468 ofthe alignment element 460, 465) operably extends the plunging body 66,466, 566, 666, 766 without rotating the plunging body 66, 466, 566, 666,766 with respect to the engaged second structural element 37.

Still further methodology may include contact between the plunging body66, 466, 566, 666, 766 and the drive member 464, 564, 664, and 764 beingat least partially facilitated by a spring 469, 569, (664 and 764 notshown in side view, but similar in structure and functionality)positioned between the plunging body 466, 566, 666, 766 and the head420, 520, 620, 720 to exert force upon the plunging body 466, 566, 666,766 in a direction toward the drive member 464, 564, (664, 764 notshown).

Even further still, additional structural connection aligningmethodology may include the head 20, 420, 620, 720 being removablyconnected to a respective handle 50, 450, 650, 750 the head 20, 420,620, 720 being configured to open or close as the handle 50, 450, 650,750 is squeezed or spread. Moreover, the structural connection aligningmethodology may include the provision of another alignment element 60,460, 465, 560, 660, 760 being attached to the head 20, 420, 520, 620,720 wherein the other alignment element 60, 460, 465, 560, 660, 760 alsoincludes a respective plunging body 66, 466, 566, 666, 766 configured toengage the second structural element 37 and move the second structuralelement 37 into alignment with the first structural element 36.

In addition, an embodiment of a structural connection aligning methodmay include setting a tack weld gap 38 via extension of a tack shim 105from the head 20, 420, 520, 620, 720. Having accurately and preciselyaligned the structural elements 36 and 37, the tack weld gap 38typically then is set using the tack weld gap shim 105. A tack weld shimend 106 of the tack shim 105 is inserted between the ends of thestructural elements 36 and 37 via the adjustment head 108. In thisexample, the tack shim 106 comprises a threaded shaft 107 and a conicalend 106 that is demarcated. The head 108 is turned or rotated in aclockwise direction causing the shim 105 and more specifically theconical end 106 to move towards/into the tack weld gap 38. For example,each demarcation may be equivalent to 4 mm of space between the ends ofthe structural elements 36 and 37. Inserting the end 106 of the tackshim 105 to the 4^(th) demarcation may be equivalent to setting the tackweld gap 38 to 16 mm.

Alternatively, each demarcation could be equivalent to 1 mm, 2 mm, 3 mmor any unit of distance typically used for tack weld gaps 38 and tackwelding conditions. The tack weld gap 38 can be set from about ⅛ inch toabout ⅕ inch. After having set the tack weld gap 38, a user may thenconnect and tack weld the ends of the structural elements 36 and 37knowing that the structural elements 36 and 37 have been accurately andprecisely aligned using the aligning device 1, 4, 5, 6, 7 and the tackweld gap 38 is set per the user's requirement. The pipe aligning device1, 4, 5, 6, 7 engaging the structural elements 36 and 37, aligned forproper connection and having a chosen tack weld gap 38, may be heldand/or operated by one hand while the user's other hand may be utilizedto hold and operate a welding torch for subsequent tack welding. Aftertack welding is completed, the user removes the tack weld shims 105 fromthe tack weld gap 38 and may finish welding or otherwise connecting theproperly aligned and tack-joined structural elements 36, 37

While this invention has been described in conjunction with the specificembodiments outlined above, it is evident that many alternatives,modifications and variations will be apparent to those skilled in theart. Accordingly, the embodiments of the invention as set forth aboveare intended to be illustrative, not limiting. Various changes may bemade without departing from the spirit and scope of the invention. Thus,the foregoing description of the embodiments of this invention has beenpresented for purposes of illustration and description. It is notintended to be exhaustive or to limit the invention to the precise formdisclosed, and obviously, many modifications and variations arepossible. Such modifications and variations that may be apparent to aperson skilled in the art are intended to be included within the scopeof this invention as defined by the accompanying claims.

1. A structural connection aligning device comprising: an alignmenthead; at least one alignment element attached to the alignment head, theat least one alignment element having a plunging body extendable fromthe alignment head; and a drive member operable with the alignmentelement, wherein plunging body is prevented from rotating when the drivemember contacts the plunging body to move the plunging body.
 2. Thedevice of claim 1, wherein the at least one alignment element isremovably attached to the alignment head.
 3. The device of claim 1further comprising a spring contacting the plunging body and operable toexert a force against the plunging body causing the plunging body toremain in contact with the drive member.
 4. The device of claim 1,wherein the plunging body includes a contact area contoured to match theouter surface shape of a structural element to be aligned by thealigning device.
 5. The device of claim 1, wherein the drive member is ahex-head jack screw.
 6. The device of claim 2, wherein the at least onealignment element is threadably attached to the alignment head.
 7. Thedevice of claim 2, wherein the at least one alignment element is pressfit into the alignment head and secured thereto with a pin.
 8. Thedevice of claim 1, wherein the plunging body operates with a cartridgeso that neither the plunging body nor the cartridge can substantiallyrotate with respect to the other.
 9. The device of claim 8, wherein theplunging body includes a dimple and the interior of the cartridgeincludes a vertical slot running parallel to the central axis of thealignment element, and wherein a ball bearing is positioned within thedimple of the plunging body and also within the vertical slot tosecurely retain the plunging body and the cartridge in axiallynon-rotatable relation to each other while still permitting linear axialmovement of the separate components.
 10. The device of claim 1, whereinthe drive member includes a ball and operates by threadably engaging thealignment head.
 11. The device of claim 1, wherein the plunging body ismoved to contact a second structural element.
 12. A structuralconnection aligning device comprising: an alignment head configured tobe removably secured proximate an end of a first structural element; andan alignment element attached to the alignment head, the alignmentelement having a rotatably secured plunging body that extends from thealignment head and engages an end of a second structural element whenthe alignment head is removably secured proximate the end of the firststructural element.
 13. The device of claim 12, wherein the alignmentelement further comprises a drive member that contacts the plunging bodyto move and extend the plunging body.
 14. The device of claim 12,wherein the alignment head is removably secured proximate the end of thefirst structural element via tack welding a base of the head to thefirst structural element.
 15. The device of claim 12, wherein thealignment head is removably secured proximate the end of the firststructural element via operation of a handle which moves the head sothat at least a portion of the device securely engages the firststructural element.
 16. A structural connection aligning methodcomprising: providing an end of a first structural element and an end ofa second structural element to be connected; providing an aligningdevice including a head configured to be removably positioned proximatethe end of the first structural element, the aligning device furtherincluding an alignment element attached to the head, the alignmentelement having a rotatably secured plunging body extendable from thehead; extending the plunging body from the head to non-rotatably engagethe second structural element; and moving the non-rotatably engagedsecond structural element via extension of the plunging body to alignthe end of the second structural element with the end of the firststructural element.
 17. The method of claim 16, wherein the plungingbody of the alignment element is extended by contact forces exerted by adrive member of the alignment element, such that the drive memberoperably extends the plunging body without rotating the plunging bodywith respect to the engaged second structural element.
 18. The method ofclaim 17, wherein contact between the plunging body and the drive memberis at least partially facilitated by a spring positioned between theplunging body and the head to exert force upon the plunging body in adirection toward the drive member.
 19. The method of claim 16, whereinthe head is removably connected to a handle, the head being configuredto open or close as the handle is squeezed or spread.
 20. The method ofclaim 16, further comprising setting a tack weld gap via extension of atack shim from the head.
 21. A structural connection aligning devicecomprising: an alignment head; at least one alignment element attachedto the alignment head, the at least one alignment element having aplunging body extendable from the alignment head, wherein the plungingbody includes a contact area contoured to match the curved outer surfaceshape of a structural element to be aligned by the aligning device; anda drive member, wherein the drive member contacts the plunging body tomove the plunging body.
 22. The device of claim 21, wherein the drivemember moves the plunging body without rotating the plunging body. 23.The device of claim 21 further comprising a pressure mechanismconfigured to assist a movement of the alignment head.